Titanium-based compositions as well as titanium composites such as carbide-reinforced titanium composites are disclosed herein. More specifically, composite materials comprising a titanium metal matrix and titanium carbide dispersed in the matrix are disclosed. The composite materials comprise about 0.5 wt. % to about 3.0 wt. % of carbon, based on the total weight of titanium and carbon in the composite materials. Compositions comprising a titanium-based powder and at least one of a carbon-based material and a binder are also disclosed. The compositions comprise about 0.5 wt. % to about 3.0 wt. % of carbon-based material, based on the total weight of the titanium-based powder and the carbon-based material.

Mixed powder that contains first hard particles, second hard particles, graphite particles, and iron particles is used to manufacture a sintered alloy. The first hard particle is a Fe—Mo—Cr—Mn based alloy particle, the second hard particle is a Fe—Mo—Si based alloy particle. The mixed powder contains 5 to 50 mass % of the first hard particles, 1 to 8 mass % of the second hard particles, and 0.5 to 1.0 mass % of the graphite particles when total mass of the first hard particles, the second hard particles, the graphite particles, and the iron particles is set as 100 mass %.

Mixed powder that contains first hard particles, second hard particles, graphite particles, and iron particles is used to manufacture a sintered alloy. The first hard particle is a Fe—Mo—Cr—Mn based alloy particle, the second hard particle is a Fe—Mo—Si based alloy particle. The mixed powder contains 5 to 50 mass % of the first hard particles, 1 to 8 mass % of the second hard particles, and 0.5 to 1.0 mass % of the graphite particles when total mass of the first hard particles, the second hard particles, the graphite particles, and the iron particles is set as 100 mass %.

Process for formation of composite coatings and composite coatings formed thereby. A process for formation of a metal-matrix composite coating on a surface of a substrate is provided. The substrate is an aluminum alloy. The metal-matrix composite coating is formed on the substrate through laser deposition using filler materials comprising aluminum, silicon and graphite. The particles forming the metal-matrix composite coating are formed in-situ from the filler materials. A metal-matrix composite coating obtained by the laser deposition process with in-situ formation of particles is also provided.

An aluminum-based composite material includes an aluminum parent phase, and stick-shaped or needle-shaped dispersive matter of aluminum carbide dispersed in the aluminum parent phase. A method of manufacturing the aluminum-based composite material includes a step of mixing aluminum powder having a purity of 99% by mass or higher with a stick-shaped or needle-shaped carbon material, and pressing and molding a resulting mixture, so as to prepare a compacted powder body. The manufacturing method further includes a step of heating the compacted powder body at 600C to 660C to react the carbon material with aluminum in the aluminum powder, so as to disperse the stick-shaped or needle-shaped dispersive matter of aluminum carbide in the aluminum parent phase.

An aluminum-based composite material includes an aluminum parent phase, and stick-shaped or needle-shaped dispersive matter of aluminum carbide dispersed in the aluminum parent phase. A method of manufacturing the aluminum-based composite material includes a step of mixing aluminum powder having a purity of 99% by mass or higher with a stick-shaped or needle-shaped carbon material, and pressing and molding a resulting mixture, so as to prepare a compacted powder body. The manufacturing method further includes a step of heating the compacted powder body at 600C to 660C to react the carbon material with aluminum in the aluminum powder, so as to disperse the stick-shaped or needle-shaped dispersive matter of aluminum carbide in the aluminum parent phase.

A powder composition is used for the fabrication of casting inserts, designed to produPce local composite zones resistant to abrasive wear. The composite zones are reinforced with carbides and borides or with mixtures thereof formed in situ in castings. The powder includes powder reactants of the formation of carbides and/or borides selected from the group of TiC, WC, ZrC, NbC, TaC, TiB.sub.2, ZrB.sub.2, or mixtures thereof. The carbides and/or borides forming after crystallization particles reinforces the composite zones in castings. The powder composition further includes moderator powders in the form of a mixture of metal powders, which after crystallization form matrix of the composite zone in casting. A casting insert is disclosed for the fabrication in casting of local composite zones resistant to abrasive wear. A method for the fabrication of local composite zones in castings uses for this purpose the reaction of the self-propagating high temperature synthesis (SHS).

A crushing or wear part includes an un-reinforced steel alloy body and at least one in-situ cast localized composite wear zone disposed in the steel alloy body formed of metal carbide or metal boride particles selected from TiC, ZrC, WC, NbC, TaC, TiB.sub.2, and ZrB.sub.2 distributed in a steel alloy matrix. The at least one in-situ cast localized composite wear zone has a Vickers Hardness that is at least 700 and at least 50% greater than a Vickers Hardness of the un-reinforced steel alloy body. A bonding region that is located between the in-situ cast localized composite wear zone and the steel alloy body is continuous and free of cracks, and the in-situ cast localized composite wear zone is unfragmented.

A crushing or wear part includes an un-reinforced steel alloy body and at least one in-situ cast localized composite wear zone disposed in the steel alloy body formed of metal carbide or metal boride particles selected from TiC, ZrC, WC, NbC, TaC, TiB.sub.2, and ZrB.sub.2 distributed in a steel alloy matrix. The at least one in-situ cast localized composite wear zone has a Vickers Hardness that is at least 700 and at least 50% greater than a Vickers Hardness of the un-reinforced steel alloy body. A bonding region that is located between the in-situ cast localized composite wear zone and the steel alloy body is continuous and free of cracks, and the in-situ cast localized composite wear zone is unfragmented.

A hierarchical composite wear component may have a reinforcement in the most exposed part to wear, the reinforcement including a three-dimensionally interconnected network of periodically alternating millimetric ceramic-metal composite granules with millimetric interstices. The ceramic-metal composite granules have at least 52 vol %, preferably at least 61 vol %, more preferably at least 70 vol % of micrometric particles of titanium carbide embedded in a first metal matrix. The ceramic-metal composite granules have a density of at least 4.8 g/cm.sup.3. The three-dimensionally interconnected network of ceramic-metal composite granules with its millimetric interstices is embedded in the second metal matrix. The reinforcement has on average at least 23 vol %, more preferably at least 28 vol %, most preferably at least 30 vol % of titanium carbide, the first metal matrix being different from the second metal matrix, the second metal matrix including a ferrous cast alloy.